Conductix-Wampfler 91008-111-3090673 User manual

Operation Manual
Track Supply 16 kW Module
80 A/125 A at 400-415 V/440 V/480 V/277 V
BAL9100-0123g-EN
www.conductix.com translated document page 1/56
Part Number
91008
-111-3090673 ( 80 A, 400-415 V, RAL 7016)
91012
-111-3090674 (125 A, 400-415 V, RAL 7016)
91008
-111-3090675 ( 80 A, 480/277 V, RAL 7016)
91012
-111-3090676 (125 A, 480/277 V, RAL 7016)
91000
-111-3090677 (configurable version)

Operation Manual
Track Supply 16 kW Module
80 A/125 A at 400-415 V/440 V/480 V/277 V
BAL9100-0123g-EN
www.conductix.com translated document page 2/56
Index
1General Advice ........................................................................................................................................................................... 5
1.1. Information to these Operating Instructions................................................................................................................. 5
1.2. Limitation of Liability .................................................................................................................................................... 5
1.3. Copyright ..................................................................................................................................................................... 6
1.4. Spare Parts.................................................................................................................................................................. 6
1.5. Warranty...................................................................................................................................................................... 6
1.6. Customer Service ........................................................................................................................................................ 6
2Symbols and Hints ...................................................................................................................................................................... 7
2.1. Requirements Regarding Personnel ........................................................................................................................... 8
2.1.1. Qualification.................................................................................................................................................................. 8
2.1.2. Unauthorized Persons.................................................................................................................................................. 8
2.2. Application in Accordance with the Regulations.......................................................................................................... 9
3Advisory Information for the User ............................................................................................................................................. 10
4Brief Technical Description ....................................................................................................................................................... 11
5Appearance............................................................................................................................................................................... 11
6Technical Data .......................................................................................................................................................................... 12
6.1. Electrical Data | Specifications .................................................................................................................................. 12
6.1.1. Electrical Power Data | Specifications for all Versions............................................................................................... 12
6.1.2. Electrical Input Values | Specifications for Versions with 400-415 V ......................................................................... 12
6.1.3. Electrical Input Data | Specifications for Versions with 440 V.................................................................................... 13
6.1.4. Electrical Input Data | Specifications for Versions with 480 V / 277 V........................................................................ 13
6.2. Physical Data............................................................................................................................................................. 13
6.3. Environmental Data ................................................................................................................................................... 14
6.4. Mechanical Data........................................................................................................................................................ 16
6.5. Interfaces................................................................................................................................................................... 18
6.6. General Features....................................................................................................................................................... 19
6.7. Design Standards...................................................................................................................................................... 19
6.7.1. Design Standards for 400-415 V and 440 V Versions................................................................................................ 19
6.7.2. Additional Design Standards for 480/277 V Versions ................................................................................................ 19
6.8. Protection Features of Track Supply ......................................................................................................................... 19

Operation Manual
Track Supply 16 kW Module
80 A/125 A at 400-415 V/440 V/480 V/277 V
BAL9100-0123g-EN
www.conductix.com translated document page 3/56
6.9. Grounding.................................................................................................................................................................. 20
7Control Board Hardware and Fault Indication........................................................................................................................... 20
7.1. Track Supply Control Board (for specially trained personnel only)............................................................................ 20
7.1.1. Control Board LED Indication..................................................................................................................................... 21
7.2. Track Supply Display Board ...................................................................................................................................... 21
7.2.1. LED Indication............................................................................................................................................................ 22
7.2.2. Software Version Number .......................................................................................................................................... 24
7.2.3. Modes of Operation.................................................................................................................................................... 24
7.2.4. Setting Language, Time and Date.............................................................................................................................. 25
7.2.5. Warning Messages..................................................................................................................................................... 26
7.2.6. Error Codes................................................................................................................................................................ 26
8Fuses ........................................................................................................................................................................................ 29
9Transport, Packaging and Storage ........................................................................................................................................... 30
9.1. Transport ................................................................................................................................................................... 30
9.1.1. Safety Instructions for Transport ................................................................................................................................ 30
9.1.2. Transport Inspection................................................................................................................................................... 30
9.2. Packaging.................................................................................................................................................................. 31
9.3. Storage of Packages ................................................................................................................................................. 31
10 Installation................................................................................................................................................................................. 32
10.1. Who is allowed to do the Installation? ....................................................................................................................... 32
10.2. General Installation Recommendations..................................................................................................................... 32
10.3. Place and Conditions of Installation .......................................................................................................................... 33
10.4. Electrical Regulations ................................................................................................................................................ 33
10.5. Electrical Connection................................................................................................................................................. 34
10.5.1. Mains Connection (X2)............................................................................................................................................... 34
10.5.2. Configuration of Control Plug (X3) ............................................................................................................................. 35
10.5.3. Connection Track Cable (X1)..................................................................................................................................... 36
10.5.4. Layout of the External Connections (X1, X2, X3, X4, X5).......................................................................................... 37
10.5.5. Wiring of the Track Supply ......................................................................................................................................... 38
11 Warnings and Precautions........................................................................................................................................................ 41
12 Commissioning ......................................................................................................................................................................... 42
12.1. Safety ........................................................................................................................................................................ 42
12.2. System Conditions..................................................................................................................................................... 43

Operation Manual
Track Supply 16 kW Module
80 A/125 A at 400-415 V/440 V/480 V/277 V
BAL9100-0123g-EN
www.conductix.com translated document page 4/56
12.3. System Protection ..................................................................................................................................................... 43
13 Start and Operation................................................................................................................................................................... 44
14 Switching-off ............................................................................................................................................................................. 46
15 Emergency Measures ............................................................................................................................................................... 46
16 Fault Diagnosis ......................................................................................................................................................................... 47
17 Maintenance and Servicing....................................................................................................................................................... 48
18 Repair ....................................................................................................................................................................................... 49
19 Disassembly and Disposal........................................................................................................................................................ 50
19.1. Safety ........................................................................................................................................................................ 50
19.2. Reuse ........................................................................................................................................................................ 50
19.3. Disassembly .............................................................................................................................................................. 51
19.4. Disposal..................................................................................................................................................................... 51
20 Spare Parts ............................................................................................................................................................................... 52
21 Tools ......................................................................................................................................................................................... 53
22 Commissioning Report.............................................................................................................................................................. 54
23 Inspection Report...................................................................................................................................................................... 55
This Operating Instruction is based on the following IPT-Technology-Documentation-No.: OM9100-0123f-EN!
Important:
This manual refers solely to the appliance described. See the system description document for information about the complete IPT®
system and the interaction between components.
Company names mentioned in this manual that are registered and protected trade names by copyright remain the property of the
companies themselves.
In order to improve the energy supply system and its function, we reserve the right to carry out technical modifications of illustrations
and statements in this operation manual.
Please find details related to a whole IPT®system in the system manuals. Always refer to the system documentation before starting
any work on the system or components within the system or before operating the system.
Reprint and duplication (even partially) are only allowed with permission from Conductix-Wampfler.
© Conductix-Wampfler GmbH 2016

Operation Manual
Track Supply 16 kW Module
80 A/125 A at 400-415 V/440 V/480 V/277 V
BAL9100-0123g-EN
www.conductix.com translated document page 5/56
1General Advice
1.1. Information to these Operating Instructions
This document describes the component specified on the cover only. The manual does not include details about the interaction of
this component with other IPT®components within a system.
For information relating to the system please read the system and project documentation. Follow these instructions during any work
on the system or operation of the system.
These installation and operating instructions allow the safe and efficient handling of the equipment.
The installation and operating instructions are part of the equipment and must be stored close to the equipment and always
available to the personnel. The personnel must have read carefully and understood these installation and operating instructions
prior to starting work. The basic requirement for safe working is the observance of all safety advice and guidelines specified in
these installation and operating instructions. Moreover you have to observe the local accident prevention guidelines and the
general regulations for the application of the equipment.
Illustrations in this documentation are for basic comprehension and can deviate from the real design of the equipment.
All stated values are based on the metric system. If units of measurement have been omitted, millimetres (mm) apply.
Complementary instructions given in track installation manuals for specific applications, i.e. MV9100-0038 for EMS systems, must
be observed at all times, if of relevance for the installation and operation of the equipment.
1.2. Limitation of Liability
All information and instructions of this operating manual have been compiled with due regard to the standards and regulations in
force, best engineering practice and the findings and experience we have accumulated over many years.
The manufacturer does not accept liability for damage due to:
-Non-observance of the operating instructions
-Improper use
-Use by untrained personnel
-Unauthorized modifications
-Technical modifications
-Use of unauthorized spare parts and accessories
-Improper installation by unqualified installation personnel
The effective volume of delivery may deviate from these explanations and descriptions in case of special design, the utilization of
additional order options or on account of the latest technical modifications.
The commitments of the supply contract, the general terms and conditions as well as the manufacturer’s terms of delivery and the
legal regulations at the time of the conclusion of contract have to be observed.
We reserve the right of technical modifications in the context of revision of useful properties and further developments.

Operation Manual
Track Supply 16 kW Module
80 A/125 A at 400-415 V/440 V/480 V/277 V
BAL9100-0123g-EN
www.conductix.com translated document page 6/56
1.3. Copyright
These installation and operating instructions are subject to copyright and intended for customer internal use only.
Providing third parties with the installation and operating instructions, duplications in any form - even in extracts - as well as reuse
and/or disclosure of the contents are not permitted without written approval of the manufacturer, except for customer internal
purposes.
Violations will be subject to damages. This will not exclude additional claims. The manufacturer is the holder of the copyright.
We reserve the right for technical modifications of illustrations and specifications in these operating instructions that serve for the
improvement of the systems and their functions.
1.4. Spare Parts
WARNING!
Safety risk due to wrong spare parts!
The utilization of wrong or faulty spare parts may cause danger to persons as well as damage,
malfunctions or total failure.
- Use only original spare parts of the manufacturer or spare parts approved by the manufacturer!
- If uncertain always contact the manufacturer.
ADVICE!
The product warranty expires with the use of unauthorized spare parts. Spare parts must be
ordered from your licensed dealer or directly from the manufacturer. Address see last page of
these instructions.
1.5. Warranty
The regulations about warranty are listed in the general business conditions of the manufacturer.
1.6. Customer Service
Our customer service is available for technical questions. For contact data see last page of these instructions. Moreover our staff is
constantly interested in new information and experiences, which will arise from the application and which might be valuable for the
improvement of our products. Please also contact our customer service in this context.

Operation Manual
Track Supply 16 kW Module
80 A/125 A at 400-415 V/440 V/480 V/277 V
BAL9100-0123g-EN
www.conductix.com translated document page 7/56
2Symbols and Hints
Warning of voltage
This symbol can be found in several places in the operating instructions where special care has to be
taken due to a voltage presence which is hazardous to people. Please observe these instructions and be
careful in those cases. Please apply all health and safety regulations to other users as well. Always
disconnect the system from the main supply prior to carrying out any work on the energy supply system.
Attention - some hints
This sign draws the attention to parts of the operating instructions where the regulations, advice and
correct operational sequence must be observed to avoid any damage or destruction to the energy supply
system and its components.
Temperature
This sign draws the attention to parts of the operating instructions, where special care must be taken
because of hot surfaces or where inductive heating of ferromagnetic material may occur and where
special measures have to be taken.
Please pass on the advice to other users as well.

Operation Manual
Track Supply 16 kW Module
80 A/125 A at 400-415 V/440 V/480 V/277 V
BAL9100-0123g-EN
www.conductix.com translated document page 8/56
2.1. Requirements Regarding Personnel
2.1.1. Qualification
WARNING!
Risk of injury due to insufficient qualification!
Incorrect handling can cause serious injuries to persons and heavy damage to property.
- All activities must be carried out by qualified staff!
The operating conditions indicate the following qualifications for the various fields of activity:
-Electrician
When the cables have been terminated correctly by authorized personnel having received instruction exclusively from
Conductix-Wampfler, further work may be performed by an electrician.
-Instructed personnel/operators
have been instructed by the operator about the tasks assigned to them and the possible dangers in case of improper
behaviour.
-Specialized staff
is able to carry out the work assigned to them and realize and avoid any dangers in this regard, based on their training,
knowledge, experiences and knowledge of the respective regulations.
-Only those persons are authorized for these works, who are expected to do their work properly. Persons with restricted
responsiveness, e.g. due to drugs, alcohol or medication, are not permitted.
-For the selection of personnel observe the age-specific and job-related prescriptions effective at the place of installation.
2.1.2. Unauthorized Persons
WARNING!
Danger caused by unauthorized personnel!
Unauthorized personnel, who do not meet the requirements described hereunder, are not familiar with
the dangers that might occur within the working area.
- Keep unauthorized personnel away from the working area.
- In case of doubt clarify authorization and qualification and dismiss unauthorized persons from the
working area in case there are any doubts remaining regarding authorization and qualification.
- Interrupt the work as long as there are unauthorized persons within the working area.

Operation Manual
Track Supply 16 kW Module
80 A/125 A at 400-415 V/440 V/480 V/277 V
BAL9100-0123g-EN
www.conductix.com translated document page 9/56
2.2. Application in Accordance with the Regulations
The equipment has been exclusively designed and constructed for the intended purpose.
WARNING!
Danger caused by application not in accordance with regulations!
Each application of the equipment not in accordance with and/or different from the regulations can
result in dangerous situations.
Only use the equipment in accordance with the regulations.
Any details of these operating instructions must be strictly observed.
The following applications of the equipment are prohibited. Applications not in accordance with
regulations are as follows:
-Application of the equipment with accessories not permitted or authorized by the manufacturer.
-Operation of the equipment by not instructed personnel.
-Operation of the equipment outdoors.
-Operation of the equipment with installation on an improper foundation/subsurface.
Any claims due to improper application are excluded.
The operator is responsible for any damage due to improper application.

Operation Manual
Track Supply 16 kW Module
80 A/125 A at 400-415 V/440 V/480 V/277 V
BAL9100-0123g-EN
www.conductix.com translated document page 10/56
3Advisory Information for the User
DANGER!
Electric shock and/or burns and other damage due to improper use!
The device is operated with high voltage and high currents.
- Do not open the device during operation.
- Do not remove covers.
- Do not insert any objects into the device.
The Track Supply has a weight of approx. 56 kg and must not be lifted or moved by an individual person. To move and position it
use only suitable equipment and follow the according instructions (see chapter 6 “Technical Data“).
WARNING!
Risk of injury due to insufficient qualification!
Improper use can result in serious injury to persons or property damage.
- All electric installation and commissioning work as well as repair work and disassembly have to be
carried out by qualified staff (IEC 364 respectively CENELEC HD 384 or DIN VDE 0100 and IEC 664
or DINVDE 0110 and national safety rules).
All installation and commissioning work as well as repair work and disassembly have to be done according to the present operation
manual. The specifications of this document have to be strictly observed. In addition, national regulations and whenever they apply
regulations specific to the industry are to be taken into account.
ADVICE!
Qualified staff, according to the safety regulations, are persons who are familiar with the
installation, assembly, commissioning and operation of the energy supply system and who have
the appropriate qualifications.
Conductix-Wampfler cannot be responsible for damage or breakdowns that have been caused by not observing the instruction
manual.
These operating instructions contain exclusively details of the Track Supply component.
We reserve the right to carry out technical modifications of illustrations and statements in this instruction manual. References to
other documents specifying the document number do not include the revision index. Refer to the project handbook for a list of
relevant documents.